Solid Works Simulation

Analysis of Machine Elements
using SolidWorks Simulation 2011
John R. Steffen,
Ph.D., P.E.
SDC
PUBLICATIONS
www.SDCpublications.com
Schroff Development Corporation
Analysis of Machine Elements using SolidWorks Simulation
CHAPTER #2
CURVED BEAM ANALYSIS

This example, unlike that of the first chapter, will lead you quickly through those aspects
of creating a finite element Study with which you already have experience. However,
where new information or procedures are introduced, additional details are included. For
consistency throughout this text, a common approach is used for the solution of all
problems.
Learning Objectives
In addition to software capabilities studied in the previous chapter, upon completion of
this example, users should be able to:
 Use SolidWorks Simulation icons in addition to menu selections.
 Apply a split line to divide a selected face into one or more separate faces.
 Simulate pin loading inside a hole.
 Use Design Checks to determine the safety factor or lack thereof.
 Determine reaction forces acting on a finite element model.
Problem Statement
A dimensioned model of a curved beam is shown in Fig. 1; English units are used.
Assume the beam material is 2014 Aluminum alloy, and it is subject to a downward
vertical force, Fy = 3800 lb, applied through a cylindrical pin (not shown) in a hole near
its upper end. The bottom of the curved beam is considered “fixed.” In this context, the
actual fixed end-condition is analogous to that at the end of a cantilever beam where
translations in the X, Y, Z directions and rotations about the X, Y, Z axes are considered
to be zero. However, recall
from Chapter 1 that Fixture
types within SolidWorks
Simulation also depend on
the type of element to which
they are applied. Therefore,
because solid tetrahedral Fy
elements are used to model
this curved beam,
Immovable restraints are
used.
Figure 1 – Three dimensional model of a curved beam.

(Dimensions in “inches”)
2-1
Design Insight
Numerous mechanical elements occur in the shape of initially curved beams.
Examples include: C-clamps, punch-press frames, crane hooks, and bicycle caliper
brakes, to name a few. This example examines the stress at section A-A shown in Fig.
2. Section A-A is chosen because it is the furthest distance from the applied force F
thereby creating reaction force R = F and the maximum bending moment M = F*L at
that location. Accordingly, classical equations for stress in a curved beam predict
maximum stress at section A-A. In this example, the validity of this common
assumption is investigated while exploring additional capabilities of the SolidWorks
Simulation software listed in the Learning Objectives on the previous page.
F = 3800 lb
A A
L = 9 in R=F
M
Figure 2 – Traditional free-body diagram of the upper portion of a curved

beam model showing applied force F acting at a hole, and reactions R =
F, and moment M acting on cut section A-A.
Creating a Static Analysis (Study)

1. Open SolidWorks by making the following selections. (Note: A “>” is used
below to separate successive menu selections).
Start>All Programs>SolidWorks 2011 (or) Click the SolidWorks 2011 icon on your
screen.
2. In the SolidWorks main menu, select File > Open… Then browse to the location
where SolidWorks Simulation files are stored and select the file named “Curved
Beam,” then click [Open].
2-2
Curved Beam Analysis
Reminder:
If you do not see Simulation listed in the main menu of the SolidWorks screen, click
Tools > Add-Ins…, then in the Add-Ins window check  SolidWorks Simulation
in both the Active Add-Ins and the Start Up columns, then click [OK]. This action
permanently adds Simulation to the main menu every time a part file is opened.
Because one goal of this chapter is to introduce and to use the Simulation icons during
the solution process, two methods of displaying these icons are outlined below. If you
performed the set-up actions outlined in the Introduction to this text, the Simulation icons
should appear (grayed out) near the top of your screen. In that case, skip to step 5.
Display Method #1
If the Simulation tab, shown in Fig. 3,
does not appear at the top left of your
screen, add it to the other tabs as Simulation
tab
follows. Otherwise, skip to the
sentence above step 4.
Figure 3 – Useful Tabs located beneath the main
menu.
3. Right-click on any of the tab names and from the pull-down menu, click to place
a check  adjacent to  Simulation. This action adds the Simulation tab
beneath the main menu.
Initially the Simulation tab and its associated toolbar contain only the Study icon.
To view more icons in the Simulation toolbar it is necessary to begin a Study.
4. In the Simulation tab begin a new Study by selecting the ▼ symbol located on
the Study icon. From the pull-down menu select New Study. The Study
property manager opens. Skip to step 6.
5. In the Simulation tab begin a new study by selecting the ▼symbol located on the
Study Advisor icon. From the pull-down menu select New Study. The
Study property manager opens.
6. In the Name dialogue box, replace Study 1 by typing Curved Beam Analysis-
YOUR NAME. Including your name along with the Study name ensures that it
is displayed on each plot. This helps to identify plotted results sent to public
access printers.
7. In the Type dialogue box verify that Static is selected as the analysis type.
8. Click [OK]  (green check mark) to close the Study property manager.
2-3
Many of the common icons are now

displayed in the Simulation tab as
shown in Fig.4. A few “grayed out”
icons are inactive at this time.
Figure 4 – Common icons associated with a
Simulation finite element analysis.
Also, an outline of the new Study is listed at the bottom of the Simulation manager tree.
We next explore a second method to display Simulation icons.
Display method #2
9. Right-click anywhere on the toolbar at top of the

screen to open the CommandManager menu
shown in a partial view in Fig. 5.
Figure 5 – CommandManager
pull-down menu.
10. Just below CommandManager at top of this menu, click to select Use
Large Buttons with Text. This action adds a brief description beneath each icon
as illustrated in Fig. 6.
Figure 6 – Partial view of the Simulation toolbar with descriptive text applied beneath
each icon.
Presuming the Simulation icons to be unfamiliar to new users, the display mode
illustrated in Fig. 6 is used in throughout the remainder of this chapter. As in other
Windows® programs, the down arrow “▼” symbol indicates that additional options are
available beneath certain icons.
Now that an icon-based work environment is established, our Study of stress in the
curved beam continues below. As in the previous example, the sequence of steps
outlined in the Simulation manager, at the left of your screen, is followed from top to
bottom as the current finite element analysis is developed.
2-4
Assign Material Properties to the Model

Part material is defined as outlined below.
1. On the Simulation tab, click to select the Apply Material icon. The
Material window opens. Alternatively, in the Simulation manager tree, right-
click the Curved Beam folder and from the pull-down menu select Apply/Edit
Material… to open the Material window shown in Fig. 7.
2. In the left column, select

SolidWorks Materials
(if not already selected).
Because the left column
typically defaults to
Alloy Steel or displays
the last material
selected, click “-” to
close the Steel folder if
necessary.
Figure 7 – Material properties are selected and/or defined

in the Material window.
3. Click the plus sign next to the + Aluminum Alloys and scroll down to select 2014
Alloy. The properties of 2014 Aluminum alloy are displayed in the right half of
the window.
4. In the right-half of this window, select the Properties tab (if not already selected),
and change Units: to English (IPS).
In the table, note the material Yield Strength is a relatively low 13997.56 psi (essentially
14000 psi). Material with a low yield strength is intentionally chosen to facilitate
discussion of Safety Factor later in this example. Examine other values in the table to
become familiar with data available in the material properties library.
Within the table, also notice that some material properties are indicated by red text, others
by blue, and some by black. Red text indicates material properties that must be specified
because a stress analysis is being performed. Conversely, material properties highlighted
in blue text are optional, and those in black text are not needed for a stress analysis.
2-5
5. Click [Apply] followed by [Close] to close the Material window. A check mark
“” appears on the Curved Beam folder to indicate a material has been selected.
Also, the material type (-2014 Alloy-) is listed adjacent to the model name.
Aside:
If at any point you wish to change the material specification of a part, such as during a
redesign, right-click the name of the particular part whose material properties are to be
changed and from the pull-down menu select Apply/Edit Material… The Material
window opens and an alternative material can be selected.
However, be aware that when a different material is specified after running a solution,
it is necessary to run the solution again using the revised material properties.
Applying Fixtures
For a static analysis, adequate restraints must be applied to stabilize the model. In this
example, the bottom surface of the model is considered “fixed.” However, because
tetrahedral elements are used to mesh this model, “immovable” restraints are applied to
the bottom surface.
1. In the Simulation toolbar click ▼ beneath the
Fixtures Advisor icon, boxed at right, and from
the pull-down menu select Fixed Geometry. The
Fixture manager opens as shown in Fig. 8.
2. Within the Standard (Fixed Geometry) dialogue box,

select the Fixed Geometry icon (if not already
selected).
3. The Faces, Edges, Vertices for Fixture field is highlighted (light blue) to
indicate it is active and waiting for the user to select part of the model to be
restrained. Rotate, and/or zoom to view the bottom of the model. Next, move the
cursor over the model and when the bottom surface is indicated, click to select it.
The surface is highlighted and fixture symbols appear as shown in Fig. 9. Also,
Face<1> appears in the Faces, Edges, Vertices for Fixture field.
2-6
If an incorrect entity (such as a vertex, edge, or the wrong

surface) is selected, right-click the incorrect item in the
highlighted field and from the pop-up menu select Delete;
then repeat step 3.
4. If restraint symbols do not appear, or if it is desired

to alter their size or color, click the down arrow
to open the Symbol Settings dialogue box, at
bottom of the Fixture property manager, and check
the  Show preview box.
5. Both color and size of the restraint symbols

(vectors in the X, Y, Z directions) can be changed
by altering values in the Symbol Settings dialogue
box of Fig. 8. Experiment by clicking the up ▲ or
down ▼ arrows to change size of restraint
symbols. A box of this type, where values can be
changed either by typing a new value or by clicking
the ▲▼ arrows, is called a “spin box.” Restraint
symbols shown in Fig. 9 were arbitrarily increased
in size to 200%.
Figure 8 – Fixture property

manager.
6. Click [OK]  (green check mark) at top of

the Fixture property manager to accept this
restraint. An icon named Fixed-1 appears
beneath the Fixtures folder in the
Simulation manager tree.
Figure 9 – Fixtures applied to

bottom of the curved beam model.
2-7
Aside:
Restraint symbols shown in Fig. 9 appear as simple arrows with a small disk added to
its tail. These symbols indicate Fixed restraints when applied to shell or beam
elements. Fixed restraints set both translational and rotational degrees of freedom to
zero (i.e., both X, Y, Z displacements and rotations (moments) about the X, Y, Z axes
are zero). However, when applied to either solid models or truss elements, only
displacements in the X, Y, and Z directions are restrained (i.e., prevented). This latter
type of restraint is referred to as Immovable. The software applies appropriate
fixtures based on element type. Watch for this subtle difference in future examples.
Applying External Load(s)

Next apply the downward force, Fy = 3800 lb, at the hole located near the top left-hand
side of the model shown in Figs. 1 and 2. This force is assumed to be applied by a pin
(not shown) that acts through the hole.
Analysis Insight:
Because the goal of this analysis is to focus on curved beam stresses at Section A-A,
and because Section A-A is well removed from the point of load application, modeling
of the applied force can be handled in a number of different ways. For example, the
downward force could be applied to the vertical surface located on the upper left side
of the model, Fig. (a). Alternatively, the force could be applied to the upper or lower
edge of the model at the extreme left side, Fig. (b). These loading situations would
require a slight reduction of the magnitude of force F to account for its additional
distance from the left-side of the model to section A-A (i.e., the moment about section
A-A must remain the same).
A A A A
Figure (a) – Force applied to left surface. Figure (b) – Force applied to lower edge.
The above loads are simple to apply. However, the assumption of pin loading allows
us to investigate use of a Split Line to isolate a portion of the bottom surface of the hole
where contact with a pin is assumed to occur. This surface is where a pin force would
be transferred to the curved beam model. The actual contact area depends on a number
of factors, which include: (a) geometries of the contacting parts (i.e., relative diameters
of the pin and hole), (b) material properties (i.e., hard versus soft contact surfaces of
either the pin or the beam), and (c) magnitude of the force that presses the two surfaces
2-8
together. This example arbitrarily assumes a reasonable contact area so that use of a
Split Line can be demonstrated. If, on the other hand, contact stresses in the vicinity of
the hole were of paramount importance, then determination of the true contact area
requires inclusion of the actual pin and use of Contact/Gap analysis. This type of
analysis is investigated in Chapter #6.
Inserting Split Lines

The first task is to isolate a portion of the area at the bottom of the hole. This can be
accomplished by using a Split Line. The method described below outlines the use of a
reference plane to insert a Split Line.
1. In the drawing toolbar, at the top center of the

graphics area, reorient the model by clicking the
Trimetric or Isometric view icon.
2. From the main menu, select Insert. Then, from succeeding pull-down menus
make the following selections: Reference Geometry ► followed by Plane… In
Fig. 10 the Plane property manager is positioned below the Simulation feature
manager.
SolidWorks
feature
manager
Simulation
feature
manager
Plane
property
manager
Figure 10 – The Plane property manager and menu selections made to create a
reference plane that passes through the bottom of the hole.
3. Within the Plane property manager, under First Reference, the field is
highlighted (light blue) to indicate it is active and awaiting selection of a plane
from which a new plane can be referenced.
2-9
Reference Plane
Offset
Distance
Spin Box
Origin
Top Plane
Figure 11 - The Plane property manager and various selections made to create a
reference plane that passes through the bottom of the hole.
4. Within the SolidWorks feature manager select the Top Plane; see arrow. The
Plane property manager changes appearance as shown in Fig. 11 and Top Plane
appears in the First Reference dialogue box. For users who opened the Curved
Beam part file available at the textbook web site, the top plane passes through the
part origin, which is located on the bottom of the model1 in Fig. 11.
5. Return to the First Reference dialogue box and in the Offset Distance spin-box
and type 14.75. This is the distance from the Top Plane to a Reference Plane
located so that it passes through the bottom portion of the hole shown in Fig. 11.
Aside:
The 14.75-in. dimension is determined from the following calculation. Refer to Fig. 1
to determine the source of values used in the equation below.
10 in (height of straight vertical sides) + 3 in (radius of concave surface) + 1.75 in (distance
from the horizontal edge beneath the hole and extending into the bottom portion of the hole) =
14.75in.
It is emphasized that the area intersected on the bottom of the hole is chosen arbitrarily
in this example!
1
Users who created a curved beam model from scratch can also follow these instructions. The only
difference would be specification of the proper distance from the Top Plane (used as a reference in your
model) to the bottom of the hole.
2-10
6. Click [OK]  to close the Plane property manager.

The reference plane, labeled Plane1, created in the preceding steps appears highlighted
on your screen. In the following steps this plane is used to create Split Lines near the
bottom of the hole. These Split Lines enable us to define a small “patch” of area on the
bottom of the hole where the downward load is to be applied.
7. From the Main Menu, select Insert. Then, from

the pull-down menus choose: Curve ► followed by
Split Line… The Split Line property manager
opens as shown in Fig. 12.
8. Beneath Type of Split, select  Intersection. This

choice designates the means by which Split Lines
are defined for this example (i.e., Split Lines will be
located where Plane1 intersects the hole).
9. In the Selections dialogue box, Plane1 should

already appear in the Splitting Bodies/Faces/
Planes field. If Plane1 does not appear in this field,
click to activate the field (light blue), then move the
cursor onto the graphics screen and select the upper
plane when it is highlighted. Plane1 now appears
in the top field.
Figure 12 – Split Line property

manager showing selections.
10. Next, click inside the Faces/Bodies to Split

field. This field may already be active (light
blue). Then move the cursor over the model Split Lines
and select anywhere on the inside surface of
the hole. It may be necessary to zoom in on
the model to select this surface. Once
selected, Face<1> appears in the active field.
Figure 13 shows a partial image of the model
with Split Lines appearing where Plane1
intersects the bottom of the hole.
Figure 13 – Close-up view of hole
showing Split Lines where Plane1
intersects near the bottom of hole.
Remain zoomed-in on the model to facilitate applying a force to the inside of the hole.
11. In the Surface Split Options dialogue box, select  Natural. A Natural split
follows the contour of the selected surface.
2-11
12. Click [OK]  to close the Split Line property manager.
13. If an information “flag” appears adjacent to the Split Lines, click  to close it.
Applying Force to an Area Bounded by Split Lines

Now that a restricted area on the bottom of the hole has been identified, the next step is to
apply a downward force, Fy = 3800 lb, on this area. Proceed as follows.
1. On the Simulation tab, click ▼beneath the External Loads… icon and from
the pop-up menu select the Force icon. A partial view of the Force/Torque
property manager appears in Fig. 14.
2. Within the Force/Torque dialogue box, click the

Force icon (if not already selected). Also,
click  Selected Direction. Then click to
activate (light blue) the upper field titled Faces,
Edges, Vertices, Reference Points for Force.
3. Move the cursor over the model and when the

bottom inside surface of the hole is outlined,
click to select it. Face<1> appears in the active
field of the Force/Torque dialogue box.
4. Next, click to activate the second field from the

top of the Force/Torque dialogue box. Passing
the cursor over this field identifies it as the Face,
Edge, Plane for Direction field. This field is
used to specify the direction of the force applied
to the bottom of the hole.
Because a downward, vertical force is to be applied,

select a vertical edge . . . any vertical edge . . . on the
model aligned with the Y-direction. After selecting a
vertical edge, Edge<1> appears in the active field and
force vectors appear on the model as seen in Fig. 15.
5. In the Units dialogue box, set Units to English

(IPS) (if not already selected).
Figure 14 – Specifying a force

and its direction on the hole
bottom.
6. In the Force dialogue box, type 3800. As noted in an earlier example, it may be
necessary to check  Reverse Direction if the force is not directed downward.
2-12
7. Click [OK]  to accept this force

definition and close the Force/Torque
property manager. An icon named
Force-1 (:Per item: 3800 lbf:) appears
beneath the External Loads folder in
the Simulation manager.
Figure 15 – Downward force applied

between Split Lines on bottom of hole.
A wireframe view of the model is shown.
The model is now complete as far as material, fixtures, and external load definitions are
concerned. The next step is to Mesh the model as described below.
Meshing the Model
1. Within the Simulation tab, select ▼beneath the Run icon. From the pull-
down menu, select the Create Mesh icon. Alternatively, in the Simulation
manager tree, right-click Mesh and from the pull-down menu select Create
Mesh… The Mesh property manager opens as shown in Figs 16 (a) and (b).
2. Check  to open the  Mesh Parameters dialogue
box and verify that a  Standard mesh is selected.
Also set the Unit field to in (if not already selected).
Accept the remaining default settings (i.e., mesh
Global Size and Tolerance) shown in this dialogue
box.
3. Click the down arrow to open the Advanced

dialogue box, Fig. 16 (b). Verify that Jacobian
points is set at 4 points. These default settings
should produce a good quality mesh. However,
verify that the settings are as listed and only change
them if they differ.
Figure 16 (a) – Mesh property

manager showing system
default Mesh settings applied to
the current model.
2-13
4. Finally, click [OK]  to accept the default mesh

settings and close the Mesh property manager.
Meshing starts automatically and the Mesh Progress

window appears briefly. After meshing is complete,
SolidWorks Simulation displays the meshed model shown
in Fig. 17. Also, a check mark “” appears on the Mesh
icon to indicate meshing is complete.
Figure 16 (b) – View of the

Advanced and Options
portions of the Mesh property
manager.
OPTIONAL:
5. Display mesh information by right-clicking the Mesh folder (not the Create Mesh
icon) and select Details...
The Mesh Details window displays a

variety of mesh information. Scroll down
the list of information and note the number
of nodes and elements for this model is
12583 nodes and 7232 elements (numbers
may vary slightly due to the automated
mesh generation procedure).
Rotate the model as illustrated in Fig. 17

and notice that the mesh is just two elements
thick. Two elements across the model’s
thinnest dimension are considered the
minimum number for which Solid Elements
should be used. Thus, two elements are
considered an unofficial dividing line
between when Shell or Solid Elements
should be used. Therefore, either element
type could be used for this model. But, keep
in mind that shell elements are typically
reserved for thin parts.
6. Click  to close the Mesh Details

window.
Figure 17 – Curved beam with mesh
and boundary conditions illustrated.
2-14
Reminder
Recall that it is permissible to define material properties, fixtures, external loads, and
create the mesh in any order. However, all these necessary steps must be completed
before running a solution.
Solution
After the model has been completely defined, the solution process is initiated. During a
solution the numerous equations defining a Study are solved and results of the analysis
are saved for review.
1. On the Simulation tab, click the Run icon to initiate the solution process.
After a successful solution, a Results folder appears

at the bottom of the Simulation manager. This folder
should include three sub-folders that contain default
plots saved at the conclusion of each Study. These
folders are named as illustrated in Fig. 18. If these
folders do not appear, follow steps (a) through (f) Note that
your name
outlined on pages 1-14 of Chapter #1. appears in
the filename
When the Results folders are displayed, alter Units
for the Stress and Displacement plots, if necessary,
as outlined below.
2. If the von Mises stress plot is not shown on the

screen, then right-click Stress1 (-von Mises-)
and from the pull-down menu, select Show. Default
Results
folders
3. Again, right-click Stress1 (-vonMises-) and
from the pull-down menu select Edit
Definition… In the Display dialogue box,
verify Units are set to psi. If not, use the pull-
down menu to change Units from N/m^2 to
psi.
Figure 18 – Results folders created
during the Solution process.
4. Click [OK]  to close the Stress Plot property manager.
5. Repeat steps (2) through (4), however, in step (2), right-click Displacement1 (-
Res disp-) and in step (3) alter the Units field from mm to in. NOTE: “Res
disp” is short for “resultant displacement.”
2-15
Examination of Results
Analysis of von Mises Stresses Within the Model
Outcomes of the current analysis can be viewed by accessing plots stored in the Results
folders listed in the previous section. This step is where validity of results is verified by
cross-checking Finite Element Analysis (FEA) results against results obtained using
classical stress equations. Checking results is a necessary step in good engineering
practice!
1. In the Simulation manager tree, double-click the Stress1 (-vonMises-) folder (or)
right-click it and from the pull-down menu, select Show. A plot of the vonMises
stress distribution throughout the model is displayed.
Figure 19 reveals an image similar to what currently appears on the screen. The
following steps convert your current screen image to that shown in Fig. 19.
Region of
maximum Stress
Areas of minimum
von Mises Stress
Figure 19 – Front view of the curved beam model showing von Mises stress after making
changes outlined below. Note arrows indicating Yield Strength on the stress scale at right.
NOTE: Stress contour plots are printed in black, white, and grey tones. Therefore, light
and dark color areas on your screen may appear different from images shown throughout
this text.
2-16
2. Right-click Stress1 (-vonMises-) and from the pull-down menu select Chart
Options… A portion of the Chart Options
property manager is shown in Fig. 20.
3. Within the Display Options dialogue box, click

to place check marks to activate  Show min
annotation and  Show max annotation.
4. Click [OK]  to close the Chart Options

property manager. The minimum and
maximum vonMises stress locations and
magnitudes are now labeled on the model.
Figure 20 – Upper portion of
Chart Options property manager
showing current selections.
5. Right-click Stress1 (-vonMises-) and from the pull-down menu select Settings….
The Settings property manager opens as illustrated in Fig. 21.
6. From the Fringe options menu, select Discrete

as the fringe type to be displayed.
7. Next, in the Boundary options pull-down

menu, select Model to superimpose an outline
of the model on the image.
8. Click [OK]  to close the Settings property

manager.
Figure 21 – Selections in the
Settings property manager.
9. In the Simulation tab, successively click the Deformed Result icon to

toggle between a deformed image of the model (default state) and an un-deformed
image. See images in Fig. 22. When done, leave the model in the un-deformed
state.
Figure 22 – Deformed and un-deformed model images.
2-17
The following observations can be made about the figure currently on your screen.
OBSERVATIONS:
 Areas of low stress (dark blue) occur at the top-left side of the model. Also
observe the dark blue region through the vertical center of the model. This
line corresponds to the neutral axis. The lowest von Mises stress is
approximately 21.3 psi. Regions of high stress are indicated in red. The
maximum stress indicated is 24861.7 psi, which occurs along the concave
surface.
 Material Yield Strength =13997.6 ≈ 14000 psi is also listed beneath the color-
coded von Mises stress legend. An arrow adjacent to the color chart indicates
where the Yield Strength lies relative to all stresses within the model. In this
instance, it is clear that some stresses in the model exceed the material yield
strength. Yield Strength and Safety Factor are investigated below.
Modern software makes conducting a finite element analysis and obtaining results
deceptively easy. As noted earlier, however, it is the validity of results and
understanding how to interpret and evaluate them that is of primary importance. For
these reasons, we pause to consider two questions that should be intriguing or, perhaps,
even bothering you, the reader.
First, why are all stress values positive in Fig. 19? (“+” stress values indicate tension).
However, compressive stresses are known to exist along the concave surface for the
given loading. Second, why does the solution show stresses that exceed the material
yield strength when stresses above the yield strength indicate yielding or failure? These,
and many others, are the types of questions that should be raised continually by users of
finite element software. Attempts to address these questions are included below.
To answer these questions, we briefly digress to investigate the definition of von Mises
stress as a means to determine a Safety Factor predicted by the software.
Von Mises Stress -

The example of Chapter 1 skirted the issue about what the von Mises stress is or what it
represents. That example further assumed that some readers might not be familiar with
von Mises stress. For the sake of completeness, and because von Mises stress typically is
not introduced until later in a design of machine elements course, its basic definition is
included below. Although this SolidWorks Simulation user guide is not intended to
develop the complete theory related to von Mises stress, the usefulness of this stress
might be summed up by the following statement-
The equation for von Mises stress “allows the most complicated stress
situation to be represented by a single quantity.”2 In other words, for the
most complex state of stress that one can imagine (e.g., a three-dimensional
stress element subject to a combination of shear and normal stresses acting
2
Budynas, R.G., Nisbett, J. K., Shigley’s Mechanical Engineering Design, 8th Ed., McGraw-Hill, 2008,
p.216.
2-18
on every face, as illustrated below) these stresses can be reduced to a single

number. That number is named the von Mises stress. This number
represents a stress magnitude, “which can be compared against the yield
strength of the material”3 to determine whether or not failure by yielding is
predicted. As such, the von Mises stress is associated with one of the
theories of failure for ductile materials; theories of failure are briefly
discussed below. The von Mises stress is always a positive, scalar number.
σy
The above statement answers the question about the positive
nature of von Mises stress shown in Fig. 19. It also should
τyx
provide some insight into why the von Mises stress, which is a
τyz τxy
single number, can be used to determine whether or not a part
τzy σx
is likely to fail by comparing it to the part yield strength (yield
strength is also a single number). The method of comparison
τzx τxz
used is the Safety Factor, which is explored later in this
σz
chapter.
Although the above definition indicates that von Mises stress is always a positive
number, that superficial answer might continue to bother readers who intuitively
recognize that compressive stresses result along the concave surface of the curved beam.
More fundamentally the issue in question gets to the heart of any analysis. That question
is, “What stress should be examined when comparing finite element results with stress
calculations based on the use of classical equations?” The answer, of course, is that one
must examine the appropriate stresses that correspond to the goals of an analysis. For
example, in Chapter 1 it was decided that normal stress in the Y-direction (σy) was the
primary stress component that would provide favorable comparisons with stresses
calculated using classic equations. The Verification of Results section below reveals the
appropriate stress for the current example. Before continuing, answer the question,
“What is the appropriate stress?” Then, check your answer below.
Verification of Results
In keeping with the philosophy that it is always necessary to verify the validity of Finite
Element Analysis (FEA) results, a quick comparison of FEA results with those calculated
using classical stress equations for a curved beam is included below.
Results Predicted by Classical Stress Equations

Although not all users may be familiar with the equations for stress in a curved beam, the
analysis below should provide sufficient detail to enable reasonable understanding of this
state of stress. The first observation is a somewhat unique characteristic of curved
beams, namely, for a symmetrical cross-section its neutral axis lies closer to the center of
curvature than does its centroidal axis. This can be observed in Fig. 23. By definition the
centroidal axis, identified as rc, is located half-way between the inside and outside radii of
curvature. However, the neutral axis, identified by rn, lies closer to the inside (concave)
3
Ibid
2-19
surface. Based on this observation, a free body diagram of the upper portion of the
curved beam is shown in Fig. 23. Included on this figure are important dimensions used
in the following calculations. Dimensions shown are defined below.
w = width of beam cross-section = 4.00 in (see Fig. 1)

d = depth (thickness) of beam cross-section = 0.75 in (see Fig. 1)
A = cross-sectional area of beam = w*d = (0.75 in)(4.00 in) = 3.00 in2
ri = radius to inside (concave surface) = 3.00 in
ro = radius to outside (convex surface) = 7.00 in
rc = radius to centroid of beam = ri + w/2 = 3.00 + 2.00 = 5.00 in
rn = radius to the neutral axis = w/ln(ro/ri) = 4.00/ln(7.00/3.00) = 4.72 in. [determined
by equation for a curved beam having a rectangular cross-section]
ci = distance from the neutral axis to the inside surface = rn – ri = 4.72 – 3.00 = 1.72 in
co = distance from the neutral axis to the outside surface = ro – rn = 7.00 – 4.72 = 2.28 in
e = distance between the centroidal axis and neutral axis = rc – rn = 5.00- 4.72 = 0.28 in
r0 = 7.00 in
Centroidal Axis
Neutral Axis
F = 3800 lb ri = 3.00 in
co = 2.28 in
ci = 1.72in
rn =4.72 in
rc = 5.00 in Fy = 3800 lb
Figure 23 – Geometry associated with calculation of stress in a curved beam.
The reaction force Fy and moment M acting on the cut section are necessary to maintain
equilibrium of the upper portion of the curved beam. Equations used to compute the
combined bending and axial stresses that result from these reactions are included below.
Each equation is of the general form,
Curved beam stress = + bending stress + axial stress
Where the “+” sign for bending stress depends on what side of the model is being
investigated. Bending stress, caused by moment M, is compressive on the concave
2-20
surface of the curved beam. Hence a minus “-” sign is assigned to the bending stress
term in equation [1]. However, on the convex side of the beam bending stress causes
tension on the beam surface thereby accounting for a “+” sign associated with the first
term in equation [2]. Reaction force Fy acts to produce a compressive stress on the cut
section. Therefore, a minus “-” sign is used with the axial stress component in both
equations [1] and [2] below. In what direction do both of these stresses act?
Stress at the inside (concave) surface:

Mci Fy (34200 in-lb)(1.72 in) 3800 lb
i      -24610 psi [1]
Aeri A (3.00 in )(0.28 in)(3.00 in) 3.00 in 2
2
Stress at the outside (convex) surface:

Mco Fy (34200 in-lb)(2.28 in) 3800 lb
0     = 11990 psi [2]
Aero A (3.00 in )(0.28 in)(7.00 in) 3.00 in 2
2
Comparison with Finite Element Results

In addition to serving as a quick check of results, this section reviews use of the Probe
tool. Both the bending and axial stresses act normal to the cut surface in Fig. 23.
Therefore, it is logical that the finite element analysis stress acting in the Y-direction (σy)
should be compared with values computed using equations [1] and [2] above. You are
encouraged to produce a plot of stress σy on your own. However, abbreviated steps are
outlined below if guidance is desired.
1. In the Simulation tab, click ▼ on the Results Advisor icon and from the pull-
down menu, select New Plot. This action opens a second pull-down menu from
which the Stress icon should be selected to open the Stress Plot property
manager.
2. In the Display dialogue box, select SY: Y Normal Stress from the pull-down
menu. Also in this dialogue box, set the Units field to display psi.
3. Click to un-check  Deformed Shape.
4. Click [OK]  to close the Stress Plot property manager. A new plot named
Stress2 (-Y normal-) now appears beneath the Results folder and a plot of stress
Sy (i.e., σy) is displayed as shown in Fig. 24. If the plot does not appear, right-
click Stress2 (-Y normal-) and select Show from the pull-down menu.
5. Right-click Stress2 (-Y normal-) and from the pull-down menu select Settings…
The Settings property manager opens.
6. Within the Settings property manager, set the Fringe Options to Discrete.
2-21
A plot of normal stress σy in the Y-direction should now appear as shown in Fig. 24. The
following observations can be made about Fig. 24.
Sign change
from “+” to “-“
Region of high
compressive stress
Region
of high
tensile
stress
Figure 24 – Plot of SY: Y Normal Stress (σy) on the curved beam model.
OBSERVATIONS for Fig. 24:

 Tensile (i.e., positive “+”) stress is shown in lime green, yellow, orange, and
red. This stress occurs along the right vertical side of the model. Because this
region is subject to tensile stress, positive “+” stress magnitudes are expected.
 Compressive (i.e., negative “-”) stress is shown by some green, light blue, and
dark blue regions located along the left vertical and in concave regions of the
model. Once again compressive stress should correspond with the user’s
intuitive sense of stress in that region.
 Max and Min stress can be labeled on the plot in the Chart Options property
manager.
 Low stress regions, corresponding to the neutral axis, or neutral plane, run
through the vertical center of the model. Notice the sign changes from “+” to “-
” in the light green color coded region of the stress chart adjacent to the model.
 Note that Yield Strength is only labeled on the vonMises stress plot.
The model is next prepared to examine stresses at section Ai-Ao shown in Fig. 25.
7. Within the Settings property manager, set the Boundary Options to Mesh. A
mesh is displayed on the model.
2-22
8. Click [OK]  to close the Settings property manager.
9. Zoom in on the model to where the curved beam section is tangent to the straight,
vertical section, shown as Ai and Ao in Fig. 25, where subscript “i” = inside and
subscript “o” = outside surface of the model.
Bo
Bi
Ai Ao
Figure 25 – Use the Probe tool to determine stress magnitudes at locations on the concave
and convex sides of the curved beam model.
10. On the Simulation tab click the icon and from the pull-down
menu, select the Probe tool icon. The Probe Result property manager
opens as shown on the left side of Fig. 25.
11. In the Options dialogue box, select  At location (if not already selected).
12. Move the cursor over the straight vertical edges on the left and right sides of the
model. Each edge is highlighted as the cursor passes over it. Click to select two
nodes, indicated by a small circle, (one on the left and one on the right) located at
the top of each line. These nodes are located at the intersection between the
straight vertical section and the beginning of the curved beam section. Selected
nodes correspond to Ai and Ao in Fig. 25. If an incorrect node is selected, simply
click  At location in the Options dialogue box to clear the current selection and
repeat the procedure. Do not close the Probe Result property manager at this
time.
The above action records the following data in the Results dialogue box: Node number,
Value (psi) of the plotted stress (σy), and the X, Y, Z coordinates of the selected node.
Also, a small information “flag” appears adjacent to each node on the model and repeats
data listed in the Results table. It may be necessary to click-and-drag column headings
to view values in the Results table.
2-23
Table I contains a comparison of results found by using classical equations and the finite
element analysis results at these locations. Rounded values are used.
Table I – Comparison of stress (σy) from classical and finite element methods at
Section A-A.
Location Manual Probe Tool Percent Difference
Calculation (psi) Results (psi) (%)
Point Ai -24610 -21619 13.8%
Point Ao 11990 14188 14.9%
Examine all values and the Percent Difference (%) column. Although, differences of
this magnitude occasionally do occur, as an engineer you should be disappointed and, in
fact, quite concerned at the significant difference between these results given the validity
of the curved beam equations. However, when results differ by this magnitude it is
always appropriate to investigate further to determine the cause for the disparity and not
simply “write off” the differences as due to the fact that two alternative approaches are
used. Can you provide a valid reason why such large differences exist?
Further thought should reveal that St. Venant’s principle is once again affecting the
results. In this instance, a traditional engineering approach would dictate using classical
equations for a straight beam in the straight
vertical segment of the model below Section A-A,
see Fig. 1 (repeated), and curved beam equations
in the portion of the model above Section A-A.
Therefore, common sense suggests that there is a
transition region between the straight and curved
segments where neither set of classical equations A A
is entirely adequate. In fact, due to the finite size
of elements in this region, it is logical to presume
that the finite element analysis provides a more
accurate solution than do classical equations in
the transition region.
Figure 1 (Repeated) – Basic geometry

of the curved beam model.
Given the above observations, we next proceed to sample stress magnitudes at Section
Bi-Bo in Fig. 25. This new section is located slightly above the transition region.
Proceed as follows.
13. Move the cursor over the curved edges of the model. Then, on the concave side,
click to select the first node above the previously selected node.
14. Next, on the convex side of the model, select the second node above the
previously selected node. This procedure selects nodes Bi and Bo in Fig. 25.
2-24
Observe the two new stress magnitudes listed in the Results dialogue box and compare
them to values listed in Table II. Nodes Bi and Bo, thus selected, lie on a radial line that
forms an approximate angle of 7.5o above the horizontal. Stress values calculated using
the classical equations are modified to account for a slight shift of the centroidal axis due
to beam curvature and for the change in angle of the axial force. Based on these values, a
comparison of classical and FEA results in Table II reveals that values differ by at most
4.0%, which is a significant improvement over the initial calculations.
Table II – Comparison of stress (σy) for classical and finite element methods at
Section Bi-Bo. (Rounded values are used)
Location Manual Probe Tool Percent Difference
Calculation (psi) Results (psi) (%)
Point Bi -24515 -23772 3.1%
Point Bo 11940 12440 4.0%
15. Click [OK]  to close the Probe Result property manager.
This concludes the verification of Finite Element results, but note that even better results
are expected at locations further from the transition region.
Assessing Safety Factor

SolidWorks Simulation provides a convenient means for the designer to determine and
view a plot of Safety Factor distribution throughout the curved beam model. To use this
capability, proceed as follows.
1. In the Simulation tab, click ▼on the Results Advisor icon and from the pull-
down menu, select New Plot. Then, from a second pull-down menu, select
Factor Of Safety. The Factor of Safety property manager opens as shown in
Fig. 26 and displays the first step of a three step procedure.
2. Read text in the yellow Message dialogue box.

This message indicates that the software
automatically selects a failure criterion to determine
the factor of safety.
3. In the upper pull-down menu of the Step 1 of 3

dialogue box, select either All or Curved Beam-
Split Line1. Because there is only one part to be
analyzed the result is the same in either case.
4. Next, in the Criterion field, second field from the

top, click the pull-down menu to reveal the four
failure criteria available for determination of the
safety factor.
Figure 26 – Factor of Safety,
Step #1 of safety factor check.
2-25
A brief overview of the four failure criteria is provided below.

 Max vonMises Stress – This failure criterion is used for ductile materials
(aluminum, steel, brass, bronze, etc.). It is considered the best predictor of
actual failure in ductile materials and, as such, provides a good indication of
the true safety factor. This criterion is also referred to as the “Distortion
Energy Theory.”
 Max Shear Stress (Tresca) – This criterion also applies to ductile materials.
However, it is a more conservative theory thereby resulting in lower predicted
safety factors. As a consequence of its conservative nature, parts designed
using this criterion may be somewhat oversized.
 Mohr-Coulomb Stress – This failure criterion is applied to the design and

analysis of parts made of brittle material (cast iron, concrete, etc.) where the
ultimate compressive strength exceeds the ultimate tensile strength (Suc > Sut).
 Max Normal Stress – Also applicable for brittle materials, this failure
criterion does not account for differences between tensile and compressive
strengths within SolidWorks Simulation. This theory is also regarded as the
least accurate of the methods available.
 Other failure criteria apply for shell

elements made of composite materials.
These criteria are not described here.
5. Because the curved beam is made of

aluminum and because a good estimate of
safety factor is desired, choose Max von
Mises Stress from the pull-down menu.
Upon making the above selection, the Factor of

Safety property manager changes to that illustrated in
Fig. 27. Immediately below the Criterion field
notice that the factor of safety check is currently
defined as
 vonMises
 1
 Limit
Figure 27 – The failure criterion is

selected in Step 1 of 3 of the
Factor of Safety dialogue box.
In other words, the previous equation is currently set to identify locations in the model
where the ratio of von Mises stress to the “limiting” value of stress (i.e., the Yield
Strength) is < 1.
2-26
Thus, the above criterion identifies locations where yielding of the model is not predicted
because model Yield Strength, the denominator, is greater than the von Mises stress, the
numerator. As initially defined, the above ratio is the inverse of the traditional safety
factor definition, where:
Safety Factor = n = strength/stress
To plot only critical regions of the part, i.e., regions where

the Yield Strength is exceeded and the safety factor is < 1,
proceed as follows –
6. Advance to the second step by clicking the right

facing arrow button at the top of the Factor of
Safety property manager. The Step 2 of 3
dialogue box appears as shown in Fig. 28. It may
be necessary to click and drag its bottom edge to
expand the Factor of Safety dialogue box.
7. In the top pull-down menu, select psi as the set of

Units to be used (if not already selected).
8. Under Set stress limit to, click to select  Yield

strength (if not already selected).
9. Do not change the Multiplication factor.
Notice that the material, 2014 Alloy aluminum, and its

Yield and Ultimate strengths for the model appear near
the bottom of this dialogue box.
Figure 28 – Step 2 of 3 in the
Factor of Safety process.
Design Insight – Focus attention near the top of the Step 2 of 3 dialogue box.
In the event that a brittle material is being analyzed using the Mohr-Coulomb or the
Max Normal Stress failure criteria, it is appropriate to select the  Ultimate strength
as the failure criterion since brittle materials do not exhibit a yield point.
The User defined option is provided for cases where a user specified material is not
found in the Material Property table.
10. Click the right facing arrow button at top of this property manager to proceed
to Step 3 of 3 in the Factor of Safety property manager shown in Fig. 29.
Two options are available for displaying the factor of safety. Brief descriptions of each
are provided below.
2-27
 Factor of safety distribution – Produces a plot of safety factor variation

throughout the entire part.
 Areas below factor of safety – A target value

of safety factor is entered in the field beneath
this option. The resulting display shows all
areas of the model below the specified safety
factor in the color red and areas with a safety
factor greater than the specified value in blue.
This approach easily identifies areas that need
to be improved during the design process.
Figure 29 – Redefinition of
Factor of Safety and values to
be displayed on the new plot.
11. Beneath Step 3 of 3, select Areas below factor of safety and type “1” in the
Factor of safety: field (if not already “1”).
At the bottom of this dialog box the Safety result field informs the user that the minimum
factor of safety is 0.563016 which indicates that the design is not safe in some regions of
the model. Recall that this value is based on a comparison between Yield Strength and
the maximum von Mises stress. (Values may vary slightly from those shown).
Also note that the above value of safety factor closely matches that computed by the
reciprocal of the equation appearing in the first Factor of Safety window. That is:
 Limit Yield Strength 13997

   0.56283
 vonMises Max. von Mises Stress  24868.9 
12. Click [OK]  to close the Factor of Safety property manager. A new plot folder,
named, Factor of Safety1 (- Max von Mises Stress-), is listed beneath the
Results folder. Also, a plot showing regions of the model where the Safety
Factor < 1.0 (red) and where the Safety Factor > 1.0 (blue) is displayed.
13. Right-click Factor of Safety1 (-Max von Mises Stress-), and from the pull-down
menu, select Chart Options… The Chart Options property manager opens.
14. In the Display Options dialogue box, check  Show min annotation and click
[OK]  to close the Chart Options property manager.
The preceding step labels the location of minimum Safety Factor on the curved beam as
shown in Fig. 30. As expected, this location corresponds to the location of maximum
compressive stress previously illustrated in Fig. 19.
2-28
The figure now on your screen

should correspond to Fig. 30.
This figure shows regions where
the factor of safety is less than 1
(unsafe regions) in red. Regions
with a factor of safety greater
than 1 (safe regions) are shown
in blue. Localized regions, along
the right and left vertical edges Key to interpret
and extending into the concave Factor of Safety
plot.
region, have a safety factor less
than one.
The line of text, circled near the Red indicates region

where FOS < 1
top-left in Fig. 30, provides a (yield predicted).
“key” to interpret safe and unsafe
regions on the model.
Figure 30 – Curved beam model showing areas where
FOS > 1 (safety predicted) and where FOS < 1 (yield
predicted).
15. Double-click Factor of Safety (-Max von Mises Stress-) and repeat steps 1
through 12 above, but this time set the Areas below factor of safety to 2 instead
of 1, in step 11. How does the plot change?
A designer can repeat the above procedure for any desired level of safety factor check.
In summary, an important aspect of the von Mises stress is that it can be used to predict
whether or not a part might fail based on a comparison of its stress value to the
magnitude of yield strength. This topic is aligned with the study of theories of failure
found in most mechanics of materials and design of machine elements texts.
Analysis Insight #1:

Faced with the fact that the above part is predicted to fail by yielding, a designer
would be challenged to redesign the part in any of several ways, depending upon
design constraints. For example, it might be possible to change part dimensions to
reduce stress magnitudes in the part. Alternatively, if part geometry cannot be
changed, a stronger material might be selected or some combination of these or other
possible remedies might be applied. Because part redesign might be considered an
open-ended problem, it is not pursued here.
2-29
Analysis Insight #2:

Return briefly to the vonMises stress plot by
double-clicking Stress1 (-vonMises-) beneath
the Results folder to display this plot.
Refer to Fig. 31 or your screen and notice that
the material yield strength (13997.6 psi) is
displayed beneath the color coded stress scale.
Also, an arrow appears adjacent to the stress
scale at a magnitude corresponding to this yield
strength. Thus, all stresses above the arrow
exceed the material yield strength. Given this
observation it is logical to ask, “What is the
meaning of stress values above the material
yield strength?”
Figure 31 – von Mises stress plot for the
curved beam model.
The answer to this question is quite straight forward. Stress values greater than the
yield strength are meaningless! Why is this true?
Recall that the stiffness approach, described in the Introduction, indicated a finite
element solution starts by determining deflection ΔL of a part subject to applied loads.
Then, based on deflection, strain is calculated as ε = ΔL/L. And finally, from strain,
stress is calculated from the relation σ = Eε. In words, the last equation states that
“stress is proportional to strain,” where the constant of proportionality E (i.e., the
modulus of elasticity) is determined from the linear portion of the stress strain curve
illustrated in Fig. 32.
Because this solution is based on a linear
analysis, stress values above the yield
strength in Fig. 31 are assumed to lie along a
linear extension of the stress-strain curve
shown dashed in Fig. 32. However, above
the yield strength, the actual stress-strain
curve follows the solid curved line where
stress is no longer proportional to strain.
Thus, stress values reported above the yield
strength are meaningless.
Figure 32 – Stress vs strain curve for a typical
elastic material shown by the solid curve.
Problems where stress exceeds the yield strength can be solved in SolidWorks
Simulation Professional where non-linear analysis capabilities are available to conduct
post-yield analysis.
2-30
Alternate Stress Display Option

Because some users might prefer more immediate feedback to identify areas where
material yield strength is exceeded, this section outlines steps to quickly identify those
regions in a part. This option is only valid for von Mises stress plots. Another restriction
is that this display option only applies to individual parts. It does not apply to assemblies
because individual parts within an assembly might be made of different materials each
with its own yield strength. Change the display as follows.
1. Beneath the Results folder, right-click Stress1

(-vonMises-) and from the pull-down menu,
select Chart Options. The Chart Options
property manager opens. The bottom portion
of this property manager is shown in Fig. 33.
2. At the bottom of this property manager, click

to open the Color Options dialogue box.
3. Place a  mark to select  Specify color for

values above yield limit and accept the default
grey color specified.
Figure 33 – Customizing displays
where stress exceeds yield
strength on von Mises plots.
4. Immediately shades of gray are displayed on regions of the model where the
Safety Factor < 1 as shown in Fig. 34. The shades of gray are unimportant.
Regions where vonMises

stress > yield strength
Figure 34 – Altered plot displays stresses greater than

the yield strength in shades of grey.
2-31
5. Because it is not desired to keep this display, click  to close the Chart Options
property manager.
The revised plot appears in Fig. 34 where all stress magnitudes greater than the material
yield strength are displayed in gray tones. Although this plot does not provide insight
into magnitude of the Safety Factor, or lack thereof, it does reinforce the concept that
stress magnitudes above the yield strength are meaningless by assigning them a non-
descriptive color.
Determining Reaction Forces

It is always good engineering practice to verify that results obtained correlate well with
the given information. One simple way to confirm that results correlate with given
information is to check whether or not reaction forces are consistent with external loads
applied to the model. This section examines how to determine reaction forces at the base
of the curved beam model. To accomplish this, proceed as follows.
1. On the Simulation tab, click ▼on the Results

Advisor icon and from the pull-down menu,
select List Result Force. The Result Force
property manager opens as shown in Fig. 35.
2. In the Options dialogue box, verify that

Reaction Force is selected.
3. In the Selection dialogue box, set Units to

English (IPS), if not already selected.
4. The Faces, Edges, or Vertices field is active

(highlighted light blue) and awaiting selection of
the entity on which the reaction force is to be
determined. Rotate the model so that its bottom
(restrained) surface is visible and click to select
it. Face<1> appears in the active field. This is
the only face where reactions occur.
5. Click the [Update] button and the Reaction

Force (lbf) table at the bottom of the property
manager is populated with data. Also, X, Y, and
Z reaction force components appear at the base of
the model along with an information “flag”.
Figure 35 – Data appearing in

the Result Force property
manager.
2-32
The Component column in this table lists names for the sum of reaction forces in the X,
Y, and Z directions and the Resultant: reaction. Reaction force magnitudes listed in the
Selection column are identical to those in the Entire Model column. This result is
expected because the entire model is restrained at only this one location.
Results interpretation is as follows:

SumX: -0.070116 (essentially zero) no force is applied to model in the X-direction
SumY: 3800.4 (essentially 3800 lb) equal and opposite to the applied force
SumZ: -0.15436 (essentially zero) no force is applied to model in the Z-direction
Resultant: 3800.4 (essentially 3800 lb = the applied force)
It should be noted that a moment reaction at the base of the curved beam is missing from
the Reaction Force table. Also, opening the Reaction Moment (lbf-in) dialogue box, at
the bottom of the property manager, reveals no data entries. This outcome does not agree
with the usual conventions for reactions associated with a free-body diagram, but it is
consistent with our understanding of Immovable restraints applied to three-dimensional
tetrahedral elements. The Immovable restraint only restricts translations in the X, Y, Z
directions at each restrained node. This observation accounts for the fact that there are
only three force reactions and no moments in the Reaction Force table of Fig. 36. Note,
however, that calculated reaction forces do not exactly match the applied forces. This
difference confirms the observation that slight mathematical errors exist.
6. Click [OK]  to close the Result Force property manager.
The reaction force results above are valid for the Entire Model. However, in many
instances a model is supported (i.e., restrained) at more than one location. In those
instances it is necessary to determine reaction forces at other locations on a model.
Performing a reaction check is quite simple and can be viewed as an additional means for
users to verify the validity of boundary conditions applied to a model.
Although a surface was selected to examine reaction forces in the above example, it
should be evident that other geometric features, such as edges or vertices can also be
selected at other restrained locations on a model.
Logging Out of the Current Analysis

This concludes an introduction to analysis of the curved beam model. It is suggested that
this file not be saved. Proceed as follows.
1. On the Main Menu, click File followed by choosing Close.
2. The SolidWorks - Save documents

before closing window opens, Fig. 36,
and provides the options of either saving
the current document or not. Select
[Don’t Save].
Figure 36 – SolidWorks window prompts
users to either save changes or not.
2-33
EXERCISES
End of chapter exercises are intended to provide additional practice using principles
introduced in the current chapter plus capabilities mastered in preceding chapters. Most
exercises include multiple parts. In an academic setting, it is likely that parts of problems
may be assigned or modified to suit specific course goals.
╬ Designates problems that introduce new concepts. Solution guidance is provided for these problems.
EXERCISE 1 – Curved Beam Stresses in a “C”- Clamp

C-clamps, like that illustrated below, must pass minimum strength requirements before
they can be qualified for general purpose use. Clamps are tested by applying equal and
opposite loads acting on the two gripping faces. Part of the federal test criteria requires
that the movable (lower) jaw be extended a certain percentage of the distance of the fully-
open state to ensure that column failure of the screw is an integral part of the test.
Presuming that the movable jaw of the clamp satisfies the prescribed test criterion,
perform a finite element analysis of the C-clamp subject to the following guidelines.
Open file: C-Clamp 2-1
 Material: Cast Carbon Steel (use S.I. units)
 Mesh: In the Mesh property manager, select Standard mesh.
 Fixture: Fixed applied to the upper gripping surface of the C-clamp.
 External Load: 950 N applied normal to the lower gripping surface.
Figure E2-1 – “C”-clamp frame and cross-section dimensions.

Stress to be determined at Section A-A. (All dimensions in mm.)
2-34
Determine the following:

a. Use classical equations to compute stress at the inside and outside surfaces of
the C-clamp frame at section A-A. Section A-A is located where the straight
and curved sections are tangent. Include a free body diagram of the lower
portion of the clamp and use curved beam equations.
b. Create a stress contour plot of von Mises stress in the frame of the C-Clamp.
Include automatic labeling of maximum and minimum von Mises stress on
this plot.
c. Use the Probe feature to produce a graph of the most appropriate stress
acting on section A-A. In other words, because values from this plot are to be
compared with manual calculations of part (a), it is necessary to choose the
corresponding stress from those available within the finite element software.
Include a descriptive title and axis labels on this graph. When using the
Probe feature, begin at the concave (left inside) surface and select nodes
across the model continuing to the outside of the “T” cross-section. Use
equation [1] to compare percent differences between classical and FEA
determination of stresses at the inside and outside surfaces.
(FEA result - classical result)

% difference  *100  [1]
FEA result
d. Assuming the C-clamp is made of a ductile material, produce a plot showing
regions where the safety factor < 2.0. Also, if the safety factor is < 1.0 at any
location within the C-clamp, produce a second plot to highlight any un-safe
regions.
EXERCISE 2 – Curved Beam Stresses in Hacksaw Frame

A common, metal-cutting “hacksaw” is shown in Fig. E2-2. A solid model of the
hacksaw is available as file: Hacksaw 2-2. The model is simplified to include two 0.125
inch diameter holes that pass through the lower left and lower right ends of the hacksaw
“backbone” labeled in Fig. E2-2. For analysis purposes, the inside surface of the left-
hand hole is to be considered Fixed (i.e. immovable). Use split lines to create a small
“patch” of area on the inside surface of the hole located at the right end of the backbone.
On this surface apply a 50 lb force induced by a tensile load in the saw blade, which is
ordinarily held in place between these two holes. Assume the following.
 Material: AISI 1020 Steel (use English units)
 Mesh: In the Mesh property manager, select  Standard mesh; use the default
mesh size.
 Units: English (IPS)
2-35
 Fixture: Fixed applied to inside of left hole.
 External Load: 50 lb applied parallel to the X-direction on the inner surface of

the right-hand hole (split lines needed; placement of these lines is user defined).
Hacksaw
backbone
Figure E2-2 – Basic geometry of a hacksaw frame. Stress is to be determined at

Section Q-Q.
a. Use classical curved beam equations to compute stress at the inside (concave) and
outside (convex) surfaces of the hacksaw frame at section Q-Q. Section Q-Q is
located where the straight and curved sections are tangent. Include a labeled free
body diagram of the right-portion of the model.
b. Include a zoomed-in image of the right-hand hole so that the 50 lb applied load
can clearly be seen to act between user specified Split Lines.
c. Create a stress contour plot of von Mises stress in the saw backbone. Include
automatic labeling of maximum and minimum von Mises stress on this plot.
d. Use the Probe feature to produce a graph of the most appropriate stress across
section Q-Q, beginning at the inside (concave) surface and continuing to the
outside (convex) surface of the backbone cross-section. Use the Stress Plot
property manager to select the appropriate stress for this plot to enable
comparison with manual calculations of part (a). Include a descriptive title and
axis labels on this graph. Also, below the graph, cut-and-paste a copy of the
Probe Results table showing values used in this comparison [see Appendix A for
procedures to copy SolidWorks images into a Word® document]. Then use
equation [1], repeated below, to compute the percent difference between classical
and finite element solutions at the inside and outside surfaces of the saw
backbone.

FEA result
2-36
e. Based on von Mises stress, create a plot showing all regions of the model where
Safety Factor < 2.2 and circle these regions on the plot. Include a software
applied label indicating the maximum and minimum values for Factor of Safety.
f. Question: If stresses at section Q-Q, calculated using both classical equations and
the finite element solution, differ by more than 4%, state the reason for this
difference and describe at least one method to reduce the percent difference
calculation at this location.
EXERCISE 3 – Stresses in a Curved Anchor Bracket

The curved beam shown in Fig. E2-3 is subject to a horizontal load applied by means of a
pin (not shown) that passes through a hole in its upper end. A solid model of this part is
available as file: Anchor Bracket 2-3. The lower-left end of the part is attached to a
rigid portion of a machine frame (also not shown). Because three-dimensional
tetrahedral elements are to be used to model this part, the restraint at this location should
be considered Immovable. Use split lines to create a small “patch” of area on the inside
surface of the 16 mm diameter hole. Locate these split lines 24 mm from the right edge
of the model. On this inner surface of the hole apply a horizontal force of 8600 N acting
in the positive X-direction (to the right). Assume the following.
 Material: AISI 1010 Steel, hot rolled bar (use SI units)
 Mesh: In the Mesh property manager, select  Standard mesh; use the
default mesh size.
 Fixture: Apply a Fixed (immovable) restraint on the inclined surface.
 External Load: 8600 N in the X-direction applied on the right, inside surface of
the 16 mm diameter hole between user defined split lines.
a. Use classical equations to compute stress at the inside (concave) surface and the
outside (convex) surface of the anchor bracket at section B-B. Section B-B passes
through the center of curvature of the curved beam and is considered to be a
vertical line. Include a labeled free body diagram of the portion of the anchor
bracket to the right of section B-B.
b. Include a zoomed-in image of the hole so that the force Fx = 8600 N can clearly
be seen to act between user specified Split Lines.
c. Create a stress contour plot of von Mises stress in the anchor bracket. Include
automatic labeling of maximum and minimum von Mises stress on this plot.
2-37
Surface is attached to
a rigid frame (fixed).
Figure E2-3 Dimensioned view of the Anchor Bracket. Stress is to be determined

at Section B-B.
d. Using von Mises stress, create a plot showing all regions of the model where
Safety Factor < 1.5 (if any). Indicate these regions, if any, by circling their
location(s) on the figure and labeling them as “FOS < 1.5”. Include a software
applied label indicating locations of maximum and minimum values of Safety
Factor.
e. Use the Probe feature to produce a graph of the most appropriate stress across
the bracket at section B-B. Begin at the inside (concave) surface and continue to
the outside (convex) surface. (See the “HINT” on next page for guidance when
making this graph). Use the Stress Plot property manager to select the
appropriate stress for this plot to enable comparison with manual calculations of
part (a) above. Add a descriptive title and axis labels to this graph.
Below the graph or on a separate page either: (a) cut-and-paste a copy of the
Probe Results table that includes values used for this comparison [See Appendix
A for procedures to copy images from SolidWorks Simulation into a Word®
document], or (b) click the Save icon located in the Report Options dialogue
box, to create an Excel spreadsheet containing all values in the Probe Results
table. [See Appendix A- pg. 7]
After determining both classical and FEA results at section B-B, use equation [1]
to compute the percent difference between classical and finite element solutions at
the inside and outside surfaces of the bracket.
FEA result
2-38
f. If results of part (e) differ by 4% or more, determine the source of error in either
the classical solution or finite element solution and correct it. If no error is found,
state why results differ by this significant percent difference.
HINT: Because the Standard mesh generation scheme within SolidWorks Simulation
creates an optimized mesh, it is probable that (a) a straight line of nodes may not exist
across the model at section B-B (thus, choose the best straight line), and (b) it is also
unlikely that node points occur exactly on a vertical line through the center of curvature.
For these reasons, and to obtain the best estimate of stress on a vertical line through
section B-B, proceed as follows.
 Zoom in on a front view of the model at section B-B.
 On the Simulation tab, select the Plot Tools icon and from the pull-down
menu, click the Probe tool icon. This action opens the Probe Results
property manager.
 In the SolidWorks feature manager, move the cursor over the Right Plane
label. This action highlights an edge view of the Right Plane, which will
assist in locating nodes closest to a vertical line at Section B-B.
Unfortunately, the line disappears when the cursor is moved, but it is very
useful none the less.
 Complete the graph using the Probe tool.
╬ EXERCISE 4 – Stresses in a Curved Photoelastic Model

(Special Topics Include: Custom material definition, and using a “Hinge”
joint for Fixture)
A curved beam model, made from a photoelastic material and subject to axial load F, is
shown in Fig. E2-4. Beams such as this might be used in an experimental stress analysis
laboratory where photoelastic techniques are studied. Photoelastic material has a unique
optical property known as birefringence. Thus, when a photoelastic model is subject to
applied loads in a field of polarized light, the light passing through the model undergoes
changes of wavelength that produce visible “fringes” within the model as shown.
Figure E2-4 – “Fringes” appearing in a photoelastic model subject to a tensile load

applied through pin joints (not shown). A grid is superimposed on the model to facilitate
locating specific stress magnitudes and directions.
2-39
These “fringes” are analogous to, but not equal to, stress contour plots produced upon
completion of a finite element analysis. In this exercise, stresses produced within the
curved beam model are examined. Dimensioned views of a typical photoelastic beam are
shown in Fig. E2-5.
C
F F
A B
Figure E2-5 – Top view (above) and front (edge) view of a curved beam model. (Dimensions:
inches)
Create a finite element model of this part that includes custom material specification,
fixtures, external loads, mesh, solution, and results analysis.
Open the file: Curved Bracket
 Material: Material properties not found in SolidWorks material library (use

custom properties below)
E = 360e3 psi Modulus of Elasticity (use English units)
ν = 0.38 Poisson’s ratio
Sy = 2200 psi Yield Strength
 Mesh: In the Mesh property manager, select a  Standard mesh; use the
default mesh size. (Although this model is very thin, use a solid mesh.)
 Fixture: Hinge Joint applied at hole on left end of the model.
 External Load: 72 lb in the X-direction applied between user defined split lines
on the inner surface of the hole located at the right end of the model.
2-40
Two aspects of this exercise are unique. First, properties of the photoelastic material are
not available in the SolidWorks material library. And second, the fixture at the left hole
of the curved bracket is considered to be a Fixed Hinge joint. Guidance in the
application of these two items is provided below.
Solution Guidance
It is assumed that the user has opened the model file and started a Study in SolidWorks
Simulation. The following instructions are to serve as a “guide;” they are less detailed
than the step-by-step procedure found in example problems.
Custom Material Specification

The recommended way to create a custom material definition is to begin with a similar
existing material and then change material properties as outlined below.
 Open the Material window by right-clicking the Curved Bracket folder and
selecting Apply/Edit Material…
 Close any open pull-down menu(s) beneath SolidWorks Materials.
 Because the photoelastic material is a special, clear “plastic like” material, open
the Custom Materials folder at the bottom of the SolidWorks Materials list.
 Next click “+” to open the Plastic folder and beneath it, select Custom Plastic.
The right side of the window is populated with property values for the current
material.
 On the Properties tab, select Units: as English (IPS).
 Adjacent to Category: make no change; change the Name: to Photoelastic
Material. The Description and Source: fields can be left blank.
 Within the Property column of the lower table notice that red, blue, and black
colors are used to indicate different Property names. Red lettering indicates
information required for a stress solution. Blue lettering indicates desirable, but
not necessary information. And, property names appearing in black are not
required for the current solution. For each red item, enter the values listed
beneath “Material” in the problem statement, but do not change the existing
value in the Mass density field. Do not alter other values listed in the table.
 Click [Apply] followed by [Close] to exit the Material window. A check “”
appears on the Curved Bracket part folder and the Name: assigned above
appears on the part folder. You have successfully defined a custom material.
Fixed Hinge Specification A Fixed Hinge joint acts like a door hinge. This joint
type allows rotation about a fixed axis on the model, but prevents translation along that
axis. A Fixed Hinge is used at the left end of the Curved Bracket to prevent
translations in the X, Y, Z directions, but allows the model to remain aligned with the
external load as the part deforms. Proceed as follows.
2-41
Solution Guidance (continued)

 Right-click the Fixtures folder and from the pull-
down menu select Fixed Hinge… The Fixture
property manager opens as shown in Fig. E2-6.
 In the Standard (Fixed Hinge) dialogue box, the

Cylindrical Faces for Fixture field is
highlighted (light blue).
 Zoom in on the left hole of the model and select

its inner surface. Face<1> appears in the
highlighted field, shown in Fig. E2-6. This
cylindrical surface has an axis perpendicular to
the model face.
Figure E2-6 – Specifying a
Fixed Hinge restraint.
 Click [OK]  to close the Fixture property manager.
A Fixed Hinge restraint allows the model to undergo rotations about the selected hole,
but no translations perpendicular to the hole. The remainder of this solution uses
previously mastered procedures.
Special Solution Note:

Due to specification of a Fixed Hinge on this model, it is highly likely that the
following warning message will appear during the Solution portion of this analysis.
Click the [ No ] button if the above Linear Static window appears and continue with the
“small displacement” Solution.
a. Use classical equations to compute stress at the inside (concave) surface and the
outside (convex) surface of the curved bracket model at section C-C. Section
C-C passes through the center of curvature and is considered to be a horizontal
2-42
line in the top view of Fig. E2-5. Include a labeled free body diagram of the
portion of the model to the right of section C-C.
b. Include a zoomed-in image of the right hole so that the external load, Fx = 72 lb,
can clearly be seen to act between user specified Split Lines on the inner surface
of the hole.
c. Create a stress contour plot showing the most appropriate stress that should be
analyzed acting across section C-C. Include automatic labeling of maximum
and minimum stresses on this plot. The most appropriate stress should
correspond to the stress calculated in part (a)
d. Use the Probe feature to produce a graph of the most appropriate stress across
section C-C, beginning at the inside (concave) surface and continuing to the
outside (convex) surface of the beam. (See the “HINT” near the end of this
problem for guidance when making this graph). Use the Stress Plot property
manager to select the appropriate stress for this plot to enable comparison with
manual calculations of part (a) above. Include a descriptive title and axis labels
on this graph.
Below the graph, or on a separate page, either: (a) cut-and-paste a copy of the
Probe Results table that includes values used for this comparison [see
Appendix A for procedures to copy SolidWorks Simulation images into a
Word® document], or (b) click the Save icon, located in the Report
Options dialogue box, to create an Excel spreadsheet containing all values in
the Probe Results table. [See Appendix A, pg. A-7]. This spreadsheet can be
inserted onto the page beneath the current graph. In either table, circle the
magnitudes of stress on the concave and convex surfaces.
After determining both classical and FEA results at section C-C, use equation
[1] (repeated below) to compute the percent difference between these results at
the concave and convex surfaces of the model.

FEA result
e. On the Probe graph created in part (d), label the distance of the neutral axis
(neutral plane) from the concave edge of the model at section C-C. Write a
brief statement indicating how this value was determined. Compare this value
with the location of the neutral axis determined using classical equations?
f. Return to the plot produced in part (c). This time, use the Probe tool to sample
stress magnitudes along the concave edge of the model beginning at point A and
proceeding from node-to-node until reaching point B. Include a graph of these
results with your analysis. Add a descriptive title and axis labels to this graph.
g. QUESTIONS: Answer the following questions on a separate page.
2-43
 Is the variation of stress through the middle of the model shown in the graph
of part (d) expected? Why?
 Is the variation of stress shown on the graph of part (f) expected? Why?
 Is the location of the neutral axis determined in part (e) located where it is
expected to occur on the curved bracket model? Does the neutral axis of a
curved member subject to axial load always occur at a location like that shown
in the plot of part (e)? Explain why or why not.
HINT: Because the mesh generation scheme within SolidWorks Simulation creates an
optimized mesh, it is probable that (a) a straight line of nodes may not exist across the
model at Section C-C, and (b) it is also unlikely that node points occur exactly on a
horizontal centerline through the center of curvature. For these reasons, and to obtain
the best estimate of stress on a straight line through the curved section, proceed as
follows.
 Zoom in on a top view of the model at section C-C.
 On the Simulation tab, select the Plot Tools icon and from the pull-down
menu, click the Probe tool icon. This action opens the Probe Results
property manager.
 In the SolidWorks feature manager, move the cursor over the Right Plane label.
This action highlights an edge view of the Right Plane, which will assist in
locating nodes closest to a vertical line at Section C-C. Unfortunately, the line
disappears when the cursor is moved, but it is very useful none the less.
Textbook Problems
In addition to the above exercises, it is highly recommended that additional curved
beam problems be worked from a design of machine elements or mechanics of
materials textbook. Textbook problems provide a great way to discover errors made in
formulating a finite element analysis because they typically are well defined problems
for which the solution is known. Typical textbook problems, if well defined in
advance, make an excellent source of solutions for comparison.
2-44

Solid Works Simulation

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Solid Works Simulation

Uploaded by

Copyright:

Available Formats

Analysis of Machine Elements

using SolidWorks Simulation 2011

CURVED BEAM ANALYSIS

 Use SolidWorks Simulation icons in addition to menu selections.

 Simulate pin loading inside a hole.

 Use Design Checks to determine the safety factor or lack thereof.

 Determine reaction forces acting on a finite element model.

Figure 1 – Three dimensional model of a curved beam.

Figure 2 – Traditional free-body diagram of the upper portion of a curved

Creating a Static Analysis (Study)

Many of the common icons are now

9. Right-click anywhere on the toolbar at top of the

Assign Material Properties to the Model

2. In the left column, select

Figure 7 – Material properties are selected and/or defined

2. Within the Standard (Fixed Geometry) dialogue box,

If an incorrect entity (such as a vertex, edge, or the wrong

4. If restraint symbols do not appear, or if it is desired

5. Both color and size of the restraint symbols

Figure 8 – Fixture property

6. Click [OK]  (green check mark) at top of

Figure 9 – Fixtures applied to

Applying External Load(s)

Inserting Split Lines

1. In the drawing toolbar, at the top center of the

6. Click [OK]  to close the Plane property manager.

7. From the Main Menu, select Insert. Then, from

8. Beneath Type of Split, select  Intersection. This

9. In the Selections dialogue box, Plane1 should

Figure 12 – Split Line property

10. Next, click inside the Faces/Bodies to Split

12. Click [OK]  to close the Split Line property manager.

Applying Force to an Area Bounded by Split Lines

2. Within the Force/Torque dialogue box, click the

3. Move the cursor over the model and when the

4. Next, click to activate the second field from the

Because a downward, vertical force is to be applied,

5. In the Units dialogue box, set Units to English

Figure 14 – Specifying a force

7. Click [OK]  to accept this force

Figure 15 – Downward force applied

Meshing the Model

3. Click the down arrow to open the Advanced

Figure 16 (a) – Mesh property

4. Finally, click [OK]  to accept the default mesh

Meshing starts automatically and the Mesh Progress

Figure 16 (b) – View of the

The Mesh Details window displays a

Rotate the model as illustrated in Fig. 17

6. Click  to close the Mesh Details

After a successful solution, a Results folder appears

2. If the von Mises stress plot is not shown on the

4. Click [OK]  to close the Stress Plot property manager.

3. Within the Display Options dialogue box, click

4. Click [OK]  to close the Chart Options

6. From the Fringe options menu, select Discrete

7. Next, in the Boundary options pull-down

8. Click [OK]  to close the Settings property

9. In the Simulation tab, successively click the Deformed Result icon to

Figure 22 – Deformed and un-deformed model images.

Von Mises Stress -

on every face, as illustrated below) these stresses can be reduced to a single

Results Predicted by Classical Stress Equations